Comparison: Screen Printing, DTG, and Heat Transfer for Custom T-Shirts

Note: Durability and cost can vary based on materials, inks, and application technique.

100% Cotton vs. 50/50 Blend vs. Tri-Blends: Your Guide to Choosing Fabrics for Custom T-Shirts

When creating custom t-shirts, the fabric you choose significantly impacts comfort, durability, appearance, and print quality. Understanding the differences between 100% cotton, 50/50 blends, and tri-blends will help you select the perfect material for your design and intended use.

100% Cotton: Softness and Breathability

100% cotton t-shirts are made entirely from natural cotton fibers, making them a classic choice for custom apparel.

Pros:
– Soft and breathable: Ideal for warm weather and everyday wear.
– Comfortable feel: Becomes softer with each wash.
– Excellent printability: Provides a smooth surface for vibrant screen printing and direct-to-garment (DTG) printing.
– Eco-friendly: Biodegradable and derived from a renewable resource.

Cons:
– Prone to shrinking: May shrink up to 5–7% if not pre-shrunk.
– Less durable: Can wear out faster with frequent washing.
– Wrinkles easily: Requires ironing for a crisp look.
– Less stretch: Offers minimal elasticity compared to blended fabrics.

Best for: Casual wear, promotional events, eco-conscious brands, and designs requiring bold, crisp prints.

50/50 Blend: The Balanced Choice

A 50/50 blend combines equal parts cotton and polyester, offering a middle ground between natural and synthetic fabrics.

Pros:
– Reduced shrinkage: More stable than 100% cotton.
– Durable and long-lasting: Resists wear and pilling.
– Slight stretch and shape retention: Holds its form better over time.
– Affordable: Often priced lower than tri-blends.

Cons:
– Less breathable: Polyester content can trap heat.
– Slightly less soft: May feel coarser than 100% cotton.
– Print quality: Can appear slightly less vibrant due to fabric texture.

Best for: Workwear, school events, budget-friendly bulk orders, and active environments where durability matters.

Tri-Blends: Luxury and Performance

Tri-blend fabrics typically combine cotton, polyester, and rayon (or sometimes modal) in ratios like 50% polyester, 25% cotton, and 25% rayon.

Pros:
– Ultra-soft, vintage feel: Smooth, lightweight, and drapes beautifully.
– Excellent drape and stretch: Ideal for fitted or fashion-forward styles.
– Color retention: Holds dye well, enhancing print vibrancy.
– Wrinkle-resistant: Maintains a polished look with minimal care.

Cons:
– Higher cost: More expensive than cotton or 50/50 blends.
– Less durable: May pill over time with heavy use.
– Care sensitivity: Often requires gentler washing to maintain quality.

Best for: Premium apparel, fashion brands, gift items, and soft-hand feel prints like distressed or vintage designs.

Choosing the Right Fabric for Your Custom T-Shirt

• For comfort and eco-friendliness: Choose 100% cotton.
• For durability and value: Go with a 50/50 blend.
• For softness and a premium look: Opt for a tri-blend.

Consider your audience, use case, budget, and design style when making your decision. Each fabric offers unique advantages—selecting the right one ensures your custom t-shirts look great and feel even better.

How to Get the Best Price for Custom T-Shirts with Images (Bulk Quantity Breaks & Artwork Tips)

Ordering custom t-shirts with images in bulk can be a cost-effective way to promote your brand, team, or event. However, maximizing your savings requires strategic planning—especially when it comes to ordering quantities and preparing artwork. Here’s how to get the best price while ensuring high-quality results.

Understand Bulk Quantity Breaks

Most screen printing and direct-to-garment (DTG) printing companies offer tiered pricing based on order volume. These are called “quantity breaks,” and they can significantly reduce your per-unit cost.

• Know the Thresholds: Common quantity breaks occur at 25, 50, 100, 250, and 500 units. For example, 24 shirts might cost $12 each, while 25 could drop to $8 each.
• Plan Ahead: If you’re close to a break point, consider increasing your order slightly to reach the next tier. The small added cost for extra shirts is often offset by the savings per unit.
• Compare Print Methods: Screen printing is more economical for large orders (50+ units), especially with simple designs. DTG printing is cost-effective for smaller runs or complex, full-color images.

Choose the Right T-Shirt Style and Material

The base cost of the shirt impacts your total price. Balance quality and budget by:

• Selecting Mid-Range Cotton: 100% cotton or cotton-poly blends offer a good mix of comfort, durability, and affordability.
• Avoiding Premium Brands Unless Necessary: Basic brands like Gildan, Hanes, or Bella+Canvas typically provide the best value for bulk printing.
• Sticking to One Style: Ordering all shirts in the same style, color, and size range helps reduce setup and handling fees.

Optimize Your Artwork for Lower Printing Costs

Your design directly affects both quality and cost. Follow these tips to save money and ensure a great print:

• Simplify the Design: Fewer colors = lower screen printing costs. Stick to 1–3 colors when possible. For DTG, full color is fine, but large solid areas use more ink and may increase cost.
• Use High-Resolution Files: Provide artwork at 300 DPI in vector format (AI, EPS, or SVG) for crisp results. Raster files (PNG, JPG) should be high-resolution and properly scaled.
• Avoid All-Over Prints: Full-shirt prints require more ink and time, increasing cost. Focus on chest, back, or sleeve prints for savings.
• Stick to Standard Print Areas: Printing on standard locations (left chest, center back) reduces setup time and cost. Unusual placements may incur extra fees.

Get Multiple Quotes and Negotiate

Don’t settle for the first quote you receive.

• Compare at Least 3 Suppliers: Look at both local print shops and reputable online vendors (like Printful, RushOrderTees, or Custom Ink).
• Ask About Setup Fees: Some vendors waive or reduce screen setup fees for larger orders. Always inquire.
• Look for Promotions: Many suppliers offer seasonal discounts, first-time buyer deals, or free shipping on bulk orders.

Order Samples First

Before committing to a large order:

• Request a Physical Sample: This lets you assess shirt quality, color accuracy, and print clarity.
• Test Washability: Check how the print holds up after washing to ensure durability.

Final Tips for Maximum Savings

• Combine Orders: If you’re part of a group or organization, pool orders together to reach higher quantity breaks.
• Plan for Sizing Variations: Use a standard size chart and collect accurate measurements to minimize returns or exchanges.
• Allow Adequate Turnaround Time: Rush orders often come with fees. Plan ahead to avoid expedited charges.

By leveraging quantity breaks, optimizing your artwork, and choosing the right supplier, you can get high-quality custom t-shirts with images at the best possible price—without sacrificing professionalism or impact.